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Environmental barrier coatings on SiC without a silicon bond coating: oxidation resistance, failure modes, and future improvements

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Abstract

Environmental barrier coatings (EBCs) are used to mitigate chemical reactions between SiC ceramic matrix composite (CMC) components and the H2O in combustion gas in turbine hot sections. CMCs are currently temperature-limited by the Si-bond coating, which melts at ~ 1414 °C. This work explores EBCs where the bond coating was removed to achieve higher operating temperatures. Various versions of enhanced roughness SiC were utilized to improve EBC adhesion to the substrates prior to 1 h furnace cycle testing in steam at 1250–1425 °C. The enhanced SiC roughness resulted in short coating lifetimes as the roughness was oxidized away with SiO2 formation. Further, isothermal furnace exposures at 1400–1600 °C showed Yb2Si2O7/Yb2SiO5 EBC microstructural changes, resulting in premature debonding from the substrates. This work provides baseline requirements for the development of both next-generation EBCs and bond coating strategies to overcome the current limitation of the Si-bond coating melting temperature.

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Data sets generated during the current study are available from the corresponding author upon reasonable request.

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Acknowledgements

The authors would like to thank J. Horenburg, D. Newberry, G. Garner, and J. Wade from ORNL for support with testing and metallography. The authors would also like to thank S. Bell and J. Jun for technical review at ORNL. This work was funded by the Advanced Turbine Program, Office of Fossil Energy, Department of Energy. This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan).

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  1. Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA

    Mackenzie Ridley & Bruce Pint

  2. The Johns Hopkins University Applied Physics Laboratory, Laurel, MD, USA

    Kenneth Kane

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Correspondence to Mackenzie Ridley.

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Ridley, M., Kane, K. & Pint, B. Environmental barrier coatings on SiC without a silicon bond coating: oxidation resistance, failure modes, and future improvements. J. Korean Ceram. Soc. (2024). https://doi.org/10.1007/s43207-024-00386-w

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